Large OEM Cast 4140 Support Roller with Shot Blasting

The material is low carbon or alloy steel,such as ZG270-500,ZG42CrMo,ZG35Mn,ASTM A27 Grade 60-30 and so on.
Our main product is for cement mill,shipbuilding,oil and gas,rolling mill,forging press,mining,crusher and so on.
We can make the casting parts according to customers' drawing from 3 to 190 tons.

Following is the chemcial composition of our ordinary material

  
It is up to customers' requirement.
 

  
Haian Haitai Casting Co.,Ltd. is established in 2003 in Huangqiao Town.

In 2007,we moved our factory to Sunzhuang town and now we can supply bigger steel castings with max. weight 45 tons.

In 2011,we built a new sand mold maiking workshop with 120 tons refinining furnace and the max. weight can be 120 tons.

In 2013,we paid more attenion on the castings for shipbuilding and started to supply marine castings for most of domestic famous shipyards.

From 2013 to 2022,we bought more and more machines to strengthen our ability from rough machining to finished machining.

In 2021,we built another new sand mold making workshop for the quick development of market requirement.

Now we monthly supply 6000 tons different castings for different customers of different industry,such as cement mill,shipubuilding,petroleum machinery,rolling mill,forging press and so on.

Application:Cement mill,shipbuilding,oil and gas,rolling mill,crusher,forging press and so on.

Some typical photos for related heavy-duty industry:

For cement mill,we are good at support roller,rotary kiln tyre,half gear,mill head,bearing housing and so on.
With rich experience,support roller,kiln tyre and half gear are our fist product.
Material can be ZG42CrMo,ZG35SiMn,28Mn6 and so on.

For shipbuilding,we have all 8 class certificate:DNV,ABS,NK,KR,RINA,CCS,BV,LR and so on.
We supplied stern boss,rudder carrier,stern tube and so on.
The material is carbon steel.

For oil and gas,the material will be ZG25CrNiMo with quenching.
 

For rolling mill and forging press:
 

 

1)Pattern making

We have our own wooden pattern making workshop.
But our company is always busy,
we also have around 10 sub-contractors for pattern making.
They help us for the pattern but will be inspected according to our rules.
We will record for every pattern inspection.

For the wooden pattern,we will only preserve it one year.
For the same casting,if the quantity is more than 10 pcs,
the pattern will be free.

2)Sand core making

We have around 80 technicans for sand core making which is divided into around 10 teams.
Most of the technicans has more than 10 years' experience.
We have two main sand mold making workshop.
The maximum travel crane can carrry 200 tons.
The area for sand mold core making is 8000 m2.
The biggest hollow pit is 87m*16m*(-3.5m)
The deepest pit is 45m*16m*(-6m)

Most of the sand core is made by silica sand with common sand inside of it.
The common sand will be used repeatly.
For some important position,such as R corner,we will use chorme ore sand.

The outside of the sand core,we will do the painting,burn and clean it.

We will assemble diffrent sand cores together and wait for pouring.

Before pouring,we will use an air tube to remove any impurities to keep the sand mold clean and dry.

The sand mold will be well protected before pouring.


3)Melting and pouring

We always do the melting after mid-night for cheaper electric charge.
And we normally do pouring in the early morning.
The maximum pouring weight can be around 250 tons.
The net weight after finished machining should be not more than 150 tons.

4)Cooling
Chemical composition

Before and after pouring,we will take the sample and check the chemical compositon.

After pouring,we will wait for different time for cooling according to casting's weight.
Normally the heavier the more time.

5)Heat treatment

The maximum size of the heat treatment furnace is 12m*9m*6m.
The size also decide the max. size we can make for the casting.
We have around 12 sets heat treatment furnace.

We only can do normalizing and tempering.
The quenching if needed will be done by our sub-contactor.

Cutting the riser,we choose thermal cutting method.
After heat treatment,we will do the mechanical property test.
We have our store for test sample preservation.
 

6)Draw the line and do the first rough machining
We can do the machining from rough to finished machining.

We have 3 to 10m vertical lathes,5x16m CNC planer type milling machine and 7 sets boring and milling machine.
 

7)NDT after rough machining

Our inspectors are qualified with related NDT certificate.
We also get approval from CNAS for our testing center.

8)Welding repair
We have rich experience for making support rollers and kiln tyres,
then there is no welding for the outside working position.
This is our special technology.

Every year we supply around 400pcs kiln tyres,930pcs support roller,170 sets gear( in two halves).


But for some other castings,if we do the welding repair,
we will do the tempering for stress relief later.

All of our welders have the SGS certficate.
 

9)Final machining
We have a lot of vertical lathes from 2.5m to 10m.
 

 

We get approval from CNAS for our laboratory.
We also have 9 class certificate,such as ABS,DNV,NK,RINA,KR,CCS,BV and so on.
 

We supply a lot of castings for cement mill,rolling mill,shipbuilding and so on.

We can do the packing according to our rules or according to customers' requirement.

 

 

Normally there is a 12 months quality warantty.

We do at least three times NDT:after rough,semi-finished and finished machining.

And also the customer will do the witness during or after finished machining.

If there is also any problem when you receive the castings,
please send us photos and detailed defects,
we will negotiate with you and make a compensation.

A third party inspection before shipment is welcomed.